101402-3872 ZEXEL 9 400 610 447 BOSCH INJECTION-PUMP ASSEMBLY 9400610447 1014023872 3863418

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 447 9400610447

ZEXEL 101402-3872 1014023872

KOMATSU 3863418 3863418

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Buy INJECTION-PUMP ASSEMBLY 101402-3872 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-3872 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9260

3. GOVERNOR 105404-5320

4. SUPPLY PUMP

105220-5960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101402-3872 as INJECTION-PUMP ASSEMBLY

108822-3284 as _

Cross reference number

BOSCH 9 400 610 447 9400610447

ZEXEL 101402-3872 1014023872

KOMATSU 3863418 3863418

Zexel num

Bosch num

Firm num

Name

101402-3872

9 400 610 447

3863418 KOMATSU

INJECTION-PUMP ASSEMBLY
4BT-C K 14BC INJECTION PUMP ASSY PE4A,5A, PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-3420

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 2.5 2.45 2.55

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 10.5

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 82.5 81.5 83.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 62 62

Boost pressure mmHg 465 465

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.5+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 9 8 10

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder ON *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 85 95

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder OFF *

Rack limit *

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-0.75

Boost pressure kPa 28 28 28

Boost pressure mmHg 210 210 210

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(10.5)

Boost pressure kPa 38 34 42

Boost pressure mmHg 285 255 315

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)The torque control spring does not operate. (4)Adjust the secondary timing before adjusting the governor. (5)RACK LIMIT (When hydraulic cylinder is OFF) (6)Boost compensator stroke: BCL (7)When the hydraulic cylinder is ON (P1)
----------
K=8 BCL=0.75+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------

Speed control lever angle

F:Full speed I:Idle (1)- (2)Stopper bolt setting
----------

----------
a=11deg+-5deg b=26deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Without return spring
----------

----------
a=0deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min

Information:

This Program can be administered aftera failure occurs. The decision whether to apply the Program is made bythe dealer. When reporting the repair, use "PS50440" as the Part numberand "7755" as the Group Number and use 135579 DTF Code. Use "96" as theWarranty Claim Description Code and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. Dealer and District are responsible fordetermining eligibility. Engine installations that are known to have airentry into fuel supply are not eligible for this program.TERMINATION DATE
April 30, 2003PROBLEM
The fuel injector tip may fail on certain 3500BMarine and Genset enginesAFFECTED PRODUCT
Group1
Model Identification Number
3508B 2HW125-1601TW249-2713DW153-161
3512B 4AW329-4282GW234-277
3512B M/AUX 1PW355-361
3516B 1NW122-1342FW183-2123CW236-242
Group2
Model Identification Number
3508B 2BM139-151
3512B 7HM207-224
3516B 8CN170-180
Group3
Model Identification Number
3512B 4TN207-3118EM317-352
3516B 8KN368-4159AN175-201
Group4
Model Identification Number
3508B 7SM229-328
Group5
Model Identification Number
3508B 3DM157-206 PARTS NEEDED
Group 1* - 0R9944
* 8 for 3508 Engines (2HW125-160, 1TW249-271, 3DW153-161)
12 for 3512 Engines (4AW329-428, 2GW234-277, 1PW355-361)
16 for 3516 Engines (1NW122-134, 2FW183-212, 3CW236-242)Group 2* - 0R8691
* 8 for 3508 Engines (2BM139-151)
12 for 3512 Engines (7HM207-224)
16 for 3516 Engines (8CN170-180)Group 3* - 0R8688
* 12 for 3508 Engines (4TN207-311, 8EM317-352)
16 for 3512 Engines (8KN368-415, 9AN175-201)Group 4* - 0R8688 ?OR- 0R8690
* 8 for 3508 Engines (7SM229-328)Group 5* - 0R8690
* 8 for 3508 Engines (3DM157-206)ACTION REQUIRED
Replace all injectors and resultant damage, perstandard repair procedures (SENR6564-04 for injector R&I).SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-5000 hrs(0-24 mos) 100% 100% 0 0 0 0
5001-10000 hrs(24-48 mos) 33.3% 50% 0 0 50% 50%
NOTE : Maximum allowable labor for injectorreplacement is 1 hour plus 0.5 hours per injector. Use labor times listedin the Time Requirement Guide for replacing the resultant damage.PARTS DISPOSITION
***** North American and Canadian Dealers*****Return Complete Injector Sets to:Caterpillar Inc.Attn: Fergal O?Shea
Service Claims Room (PS50440)
8201 N. University
Peoria, IL 61615***** All Other Dealers *****Handle the parts in accordance with your WarrantyBulletin on
warranty parts handling.